Floor Covering with Resilient Surface

ABSTRACT

A floor covering includes a wear layer having an uppermost surface and a lowermost surface, a fiber layer comprising a plurality of fibers, and a backing. The plurality of fibers have a first portion integrally joined to the lowermost surface of the wear layer, and a second portion projecting upwardly from the backing, such that the fiber layer extends between the wear layer and the backing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/687,775, filed May 1, 2012, and U.S. Provisional Patent Application No. 61/690,453, filed Jun. 27, 2012, both of which are incorporated by reference herein in their entirety.

BACKGROUND

There is a need for a floor covering that offers both the resilience of a solid surface floor covering (e.g., vinyl flooring) and the flexibility and cushioning of a textile based floor covering (e.g., carpet). There is also a continuing need for floor coverings that have unique aesthetic and/or functional properties. It is toward such a floor covering that the present disclosure is directed.

SUMMARY

This disclosure is directed generally to various floor coverings, and methods of making and using the floor coverings. The floor coverings may offer improved appearance retention properties, unique aesthetic properties, and/or numerous other functional attributes. Furthermore, the present floor coverings may provide a balance of properties offered by both tufted goods (e.g., carpet) and solid surface flooring, previously unable to be attained.

Briefly described, a floor covering according the present disclosure includes an upper side that defines a wear side of the floor covering. The wear side of the floor covering includes a resilient or semi-resilient wear layer and an underlying layer of fibers. The fibers are affixed to a backing (often referred to as a “primary backing”), for example, a woven or nonwoven material through which the fiber extend and/or are looped. The floor covering may include additional layers, for example, polymer coating layers, adhesive layers, or a cushioned or structural backing (often referred to as a “secondary backing”), as will be appreciated by those of skill in the art.

More particularly, the present disclosure generally contemplates a floor covering comprising a wear layer and a fiber layer. The wear layer has an uppermost surface and a lowermost surface. The fiber layer includes a plurality of fibers having a first portion that is integrally joined to the lowermost surface of the wear layer, and a second portion that is attached to a backing, such that the fiber layer is positioned between the wear layer and the backing. The uppermost surface of the wear layer may be generally smooth and/or substantially continuous, optionally with some textural variation. The wear layer may extend across all or a portion of the floor covering. The wear layer may also be configured to define patterns and/or various regions of varying resilient in the floor covering.

The wear layer may generally be characterized as being a substantially solid, substantially continuous, and/or substantially homogenous layer that is sufficiently flexible to resiliently flex and bend without cracking in response to, for example, the footfall of an individual walking on the floor covering, the wheels of a weighted cart rolling over the wear surface, or the base of a piece of furniture seated on the floor covering. Accordingly, the floor covering may generally offer a unique balance of resilience (e.g., resistance to wear, tearing, etc.) and cushioning that is not presently available in the market.

The use of a tufted carpet or carpet precursor to form a floor covering with a resilient surface defies conventional wisdom regarding the desired properties of tufted floor coverings, in which it is generally highly desirable for the face of the floor covering to be soft and/or plush. Accordingly, the use of heat or other process to create a floor covering with a resilient surface and underlying fiber layer is unexpected and creates a new category of floor covering products.

In particular aspect, the floor covering may comprise a wear layer having an uppermost surface and a lowermost surface, a fiber layer comprising a plurality of fibers, and a backing. The plurality of fibers may have a first portion integrally joined to the lowermost surface of the wear layer, and a second portion projecting upwardly from the backing, such that the fiber layer extends between the wear layer and the backing. The wear layer may comprise a substantially homogenous polymer layer and may have an uppermost surface that is substantially smooth. The wear layer may extend across the entire floor covering, or may extend across less than the entire floor covering. In the latter case, the wear layer may be configured to define a plurality of resilient areas of the floor covering.

Countless variations are contemplated. In one variation, the fibers of the fiber layer may be contiguous with the wear layer. In another variation, the fibers may terminate at an interface between the fibers and the wear layer, such that the fibers do not extend into the wear layer. In another variation, the wear layer and the fiber layer may each have the same chemical composition. The fibers may be formed from a polymer and the wear layer may comprise the polymer of the fibers. In yet another variation, the wear layer and the fiber layer may define a wear side of the floor covering, where the wear side of the floor covering has a thickness, and the wear layer comprises at least about 10% of the thickness of the wear side of the floor covering. In still another variation, a plurality of pores may extend through the wear layer so that the uppermost surface of the wear layer is in communication with the lowermost surface of the wear layer.

In another variation, the backing may include an upper side facing the wear layer and a lower side opposite the first side, and the floor covering may further comprise a fused backstitch layer integrally joined to the lower side of the backing sheet and to the second portion of the fibers. In one variation, the wear layer, fiber layer, and fused backstitch layer each have the same chemical composition. In still another variation, the fused backstitch layer integrally joined to the lower side of the backing sheet defines a fused base sheet, and the floor covering may further comprise an adhesive layer applied to a lower side of the fused base sheet, where the adhesive is for adhering the fused base sheet to a floor surface. If desired, a removable release layer may be in a facing, contacting relationship with the adhesive layer. In another variation, the backing is a primary backing, the fused backstitch layer integrally joined to the lower side of the backing sheet defines a fused base sheet, and the floor covering further comprises a secondary backing joined to a lower side of the fused base sheet.

The floor covering may be formed in any suitable manner. For example, the floor covering may be formed from a textile including a fibrous wear side, such as a tufted carpet or carpet precursor including a fibrous wear layer. The fibrous wear layer of the precursor floor covering may be exposed to at least one of heat and pressure, so that the free ends of the fibers are heated to a temperature above the melting point of the fibers. The molten polymer from the heated fibers flows into a unitary mass, which then is allowed to cool and solidify into a sheet-like layer integrally joined to the remainder of (i.e., the non-melted) portion of the fibers. The wear layer may be generally homogenous throughout its thickness and may be generally devoid of fibers (or polymer that retains a somewhat fibrous structure).

In particular aspect, a method of making a floor covering comprises applying heat to a textile, the textile including a plurality of fibers extending through a backing, so that the plurality of fibers have a first portion on a first side of the backing and a second portion on a second side of the backing, where the first portion of the fibers includes a free end of the plurality of fibers, where applying heat to the textile comprises applying heat to the free end of the plurality of fibers so that the free ends of the plurality of fibers melt into a molten polymer, where the molten polymer solidifies and forms a wear layer integrally connected to the plurality of fibers. In some examples, the heat may be applied at a temperature greater than a melting point of the fibers, for example, at least about 20° C. greater than a melting point of the fibers. The heat may be applied for any suitable amount of time, for example, from about 2 to about 10 seconds.

The heat may be applied to the entire surface of the textile, so that the wear layer extends across the entire floor covering. Alternatively, the heat may be applied to less than the entire surface of the textile, so that the wear layer extends across only a portion of the floor covering. As a result, the floor covering may include portions of floor covering comprising the wear layer spaced apart by unheated portions of fibers. In one example, a template including an aperture is used to direct heat to specific portions of the fibers.

If desired, heat may also be applied to the second portion of the fibers on the second side of the backing, so that the second portion of the plurality of fibers transform into a molten polymer, which solidifies and forms a fused backstitch layer integrally connected to the second side of the backing. The fused backstitch layer integrally connected to the second side of the backing defines a fused base sheet.

In one variation, an adhesive may be applied to a side of the fused base sheet opposite the wear layer for adhering the fused base sheet to a floor surface, and a release liner may optionally cover the adhesive. In another variation, the backing is a primary backing and the method further comprises joining a secondary backing to a side of the fused base sheet opposite the wear layer.

Other features, aspects, and benefits of the present invention will be evident from the following description and accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates a side view of an exemplary floor covering having a resilient surface.

FIG. 2 schematically illustrates an enlarged view of the exemplary floor covering of FIG. 1.

FIG. 3 depicts a magnified view of the wear surface of an exemplary floor covering having a resilient surface.

FIG. 4 is a magnified cross-sectional view of another exemplary floor covering having a resilient surface.

FIG. 5 is a magnified cross-sectional view of yet another exemplary floor covering having a resilient surface.

FIG. 6 is a schematic view of one exemplary process for making a floor covering having a resilient surface.

FIG. 7 depicts the wear surface of another exemplary floor covering having a resilient surface, side-by-side with the fibrous precursor used to form the floor covering.

FIG. 8 is a schematic perspective view of an apparatus for making a floor covering having a patterned resilient surface.

FIG. 9 is a schematic perspective view of another apparatus for making a floor covering having a patterned resilient surface.

FIG. 10A is a schematic perspective view of still another apparatus for making a floor covering having a patterned resilient surface.

FIG. 10B depicts an exemplary template for use in making a floor covering having a patterned resilient surface.

FIG. 10C depicts a floor covering formed using the template of FIG. 10B.

FIG. 10D depicts another exemplary template for use in making a floor covering having a patterned resilient surface.

FIG. 10E depicts a floor covering formed using the template of FIG. 10C.

Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein.

DETAILED DESCRIPTION

Referring now to the figures, wherein like parts are identified with like reference numerals throughout the several views, FIGS. 1 and 2 schematically depict an exemplary floor covering 100 having a resilient surface. The floor covering 100 generally includes a first side 102 (or wear side) of the floor covering and a second side 104 (or floor-facing side) of the floor covering.

The wear side 102 of the floor covering 100 includes a wear layer 106 having an uppermost surface 108 and a lowermost surface 110, and a fiber layer 112 comprising a plurality of fibers 112′. The fibers 112 (individually and collectively) have a first portion 114 that is adjacent to, contiguous with, and/or integrally joined to the lowermost surface 110 of the wear layer 106, and a second portion 116 that extends upwardly from a backing (e.g., primary backing) 118, such that the fiber layer is positioned between (and spaces apart) the wear layer and the backing. In some embodiments, the wear layer may extend across the entire floor covering. Alternatively, the wear layer may be formed in a pattern or other configuration that extends across less than the entire floor covering, as will be discussed further below.

The primary backing 118 may typically comprise a woven or nonwoven material, such as a polyester or polyethylene woven or nonwoven material. In some embodiments, the floor covering may include a secondary backing 120 (shown schematically with dashed lines) positioned on a side of (and in some cases joined to) the primary backing opposite the wear layer. The secondary backing may provide cushioning, stability, water resistance, and numerous other properties, as will be understood by those of skill in the art.

The uppermost surface 108 of the wear layer 106 defines a semi-resilient or resilient wear surface. In some embodiments, the wear surface may be generally planar and may have a substantially smooth and glassy appearance when viewed at a distance. When viewed up close, however, the wear surface can include small curves, ripples and other rounded surface discontinuities that can naturally during formation, as will be discussed further below. For example, FIG. 3 depicts an enlarged view of the wear surface 108 a of an exemplary floor covering according to the disclosure. As will be evident, the wear surface has a somewhat glassy overall appearance, with small textural variations or topographical features.

The relative thicknesses (i.e., heights) of the wear layer (Tw) and the underlying fiber layer (Tf) may vary depending on the desired balance of properties. For example, as shown in FIGS. 4-5, which depict enlarged cross-sectional views of exemplary floor coverings having a resilient surface, the wear layers 106 b, 106 c are relatively thin relative to the total thickness (T) of the wear side of the floor covering. In such an embodiment, the underlying fiber layer 112 b, 112 c may provide cushioning similar to that of a tufted floor covering, while the wear layer provides resistance to the formation of wear patterns or other damage.

In some examples, the wear layer may comprise at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 80%, at least about 85%, or at least about 90% of the thickness of the wear side of the floor covering.

The wear layer and fibers may generally have the same composition (i.e., chemical composition) and may generally comprise a thermoplastic polymer and, optionally, other components such as fillers, additives, extenders, or processing aids, or any combination thereof. By way of example, and not limitation, the fibers may comprise a nylon (e.g., nylon 6,6, nylon 6, or nylon 12), a polyelofin (e.g., polypropylene (PP), low density polyethylene (LDPE), or high density polyethylene (HDPE)), polytrimethylene terephthalate (PTT), polyethylene terephthalate (PET), poly(vinylidine fluoride) (PVDF, e.g., Kynar), polytetrafluoroethylene (PTFE, e.g., Goretex), para-aramid synthetic fibers (e.g., Kevlar), or acrylic (e.g., polyacrylonitrile) polymer, or any combination thereof.

Particulate additives (e.g., titanium oxide) may be present in any suitable amount, for example, from about 0.01% to 3.00% of the fiber weight. Such additives may be used to increase the surface texture of the fiber to dull reflections, increase friction, provide a unique texture, improve flame resistance (e.g., by displacing the flammable fiber components or by using fillers that provide flame retarding properties, such as phosphates and aluminum trihydrate), or any combination thereof. The wear layer and fibers may also contain natural fibers, such as wool or bamboo.

The floor covering 100 may be formed in any suitable manner. In one aspect, the floor covering may generally be formed from a textile including a fibrous wear side (i.e., comprising a plurality of fibers), such as a tufted carpet or carpet precursor that generally includes a plurality of fibers coupled to (e.g., extending through or looped through) a backing (e.g., primary backing), for example, a woven or nonwoven sheet. The free ends of the fibers (i.e., the ends distal from the primary backing) may be looped or tip sheared (i.e., cut to create loose fibrous ends). Such precursor textiles may generally have a basis weight of from about 2 to about 60 ounces per square yard.

The fibers of the precursor textile generally include a thermoplastic polymer, such as those described above. The fibers may be exposed to at least one of heat and pressure so that the free ends of the fibers are heated to a temperature above the melting point of the thermoplastic polymer. In doing so, the affected portion of the fibers (i.e., the end portion and in some instances at least an additional portion of the length) loses its fiber-like structure and the polymer flows into and defines a unitary molten mass, which is then allowed to solidify into a sheet-like layer extending along the uppermost portion of the remaining (i.e., the non-melted) fiber portions. This sheet-like wear layer is integrally joined to the remaining portion of the fibers, so that the remaining portion of the fibers supports the wear layer in a position above the primary backing. Notably, although the wear layer is integrally connected to fibers, the fibers of the fiber layer generally terminate at an interface between the fibers and the wear layer, such that the fibers do not extend substantially into the wear layer. Accordingly, the wear layer may be said to be generally homogenous throughout its thickness and generally devoid of fibers (or polymer that retains a somewhat fibrous structure).

It will be understood that since the fibers are used to form the wear layer, the fibers and wear layer may typically have the same composition of polymers, additives, etc. However, it is contemplated that in other embodiments, a mixture of different fibers (or fibers having different components) having different melting points may be used. In such an embodiment, the temperature of the heat source may be selected so that only certain fibers (or portions of fibers) would melt to define the wear layer.

In general, the wear layer may have an increased strength, hardness, and durability relative to its fibrous precursor; thus, its appearance retention properties may likewise be improved relative to its fibrous precursor. Further, the fused face materials may be less flammable (e.g., due to the decreased air flow through the floor covering) and/or may also have a lower volatile organic compound (VOC) emission rate (e.g., since VOCs may be driven off when the yarn is exposed to elevated temperatures and/or because the surface area of the fused yarn is reduced). Other properties, such as static dissipation, may also be improved.

The use of pressure during melting can alter the structure and properties of the resulting floor covering. For example, an applied pressure may increase the degree of melting (i.e., how much of the fiber height is melted) and/or may compact or compress the unmelted portion of the fibers, while still allowing the unmelted portions of the fibers to substantially retain their individual structure. By way of example, in some embodiments, an applied pressure may reduce the thickness of the wear side (relative to the original thickness of the wear side of the precursor textile) at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 80%, at least about 85%, or at least about 90%.

Thus, it will be appreciated that varying amounts of pressure may be applied to create the desired balance of properties in the resulting floor covering. For example, where greater stiffness and/or resilience is desired, for example, for high traffic applications, a greater pressure may be used to form a thicker wear layer. At the same time, however, the caliper of the underlying fibers will be reduced, so that the floor covering retains little of its original carpet-like character. Alternatively, where less resilience is needed and it is desirable to retain more carpet-like qualities, less pressure may be used to form a relatively thin wear layer on the surface of the floor covering.

Other process conditions needed to form the wear layer include, but are not limited to, the melt temperature of the fibers, the temperature of the heat source, and the duration for which the heat is applied to the free ends of the fibers. By way of example, for a melting temperature of from about 230° C. for nylon 6 to about 265° C. for nylon 6,6, the temperature of heat source may be from about 260° C. to about 290° C. with an exposure time of from about 2 to about 10 seconds to completely melt the free ends of the fibers.

In some embodiments, small apertures (e.g., perforations or pores) 124 (FIG. 2) may naturally form during the congealing and fusing stage, or may be manually created during the manufacturing process. Some of such pores may extend through the wear layer so that the uppermost surface 108 of the wear layer 106 is in communication with the lowermost surface 110 of the wear layer 106. Depending on their number and size, the pores may allow for the passage of air, water vapor and possibly liquids between the environment above the wear surface and the enclosed volume between the lowermost surface of the wear layer and the upper side of the backing 118. This can be advantageous by allowing the floor covering 100 to “breathe” with a continuous exchange of air between the outside environment and the enclosed volume, and thereby maintain the floor covering in a dry and sanitary state. In one aspect, the size of the perforations in the wear layer may be controlled to allow for the passage of air and water vapor while resisting the passage of water and other liquids.

The following figures depict several exemplary processes that may be used in accordance with the disclosure and floor coverings formed therefrom. While some processes and exemplary floor coverings are shown herein, it will be appreciated that countless others are contemplated hereby. Thus, the present disclosure should not be construed as being dependent on, or limited to, a particular process or particular floor covering embodiment.

FIG. 6 illustrates a schematic view of one exemplary process 200 for making a resilient floor covering 202. In the illustrated example, the fibers 204 of a textile precursor 202′, such as a tufted carpet having either looped or cut pile (shown with looped pile), are brought into intimate contact with a heated calendared drum or roller 206 for a predetermined amount of time (e.g., a contact or exposure time). The temperature of the heated roller is maintained at a temperature sufficient to heat the free ends (i.e., tips) 208 of the fibers to a temperature above their melting point, thereby causing the polymer to soften and flow. As the transformed textile cools, the molten polymer congeals into a substantially continuous polymer layer 210 (i.e., wear layer). The surface of the wear layer may be substantially smooth, such that it lacks sharp corners and rough edges that would otherwise feel rough to the human touch. However, as illustrated in FIG. 7, which depicts a fused floor covering (left) and unfused floor covering (right), the substantially smooth wear surface may still include small curves, ripples and other rounded surface discontinuities that form naturally form as the melted or liquefied fiber ends subsequently congeal and fuse together over the uneven fiber layer, as discussed above.

The heated calendared drum or roller may be configured to apply a minimal pressure to the fibrous precursor that allows the fibers to substantially maintain their original height and shape, even as the ends of the fibers liquefy and fuse to form the wear layer. Alternatively, the heated calendared drum or roller may be configured to apply a greater pressure that serves to compact or crush the fibers to a reduced height (e.g., as discussed above) and increase the density of the fiber matrix. It is noted that even when such fiber compression occurs, the fibers maintain their character as individual fibers, for example, as shown in FIGS. 4-5.

The calendared roller may have a constant and smooth circumferential surface along the entire axial length of the roller that can be used to apply heat evenly across the entire width of the fibrous textile. Alternatively, patterns may be imparted to portions of the floor covering using an engraved heated roller, or by placing metal sleeves including the desired pattern around a heated roller, and bringing the heated roller/sleeves into contact with the face of the floor covering to impart the desired texture, pattern, and/or design at the desired height.

For example, in the process 300 of FIG. 8, a roller 302 having a solid circumferential surface 304 that includes an embossed pattern of raised portions 306 and inset portions 308 can be heated with a hot fluid, such as steam or oil. The pattern can be formed into either the raised portions or the inset portions. When the heated roller is placed into contact with the fibrous face of the precursor material 310′ running against the circumferential surface of the roller, the raised portions that contact the fibers will melt and liquefy separate (and in some cases, alternating) regions of the fibers. The molten polymer subsequently congeals and fuses to form a floor covering 310 having fused wear layer regions 312 and unfused (i.e., unheated or unmelted) fiber regions 314.

In a related process 400 shown in FIG. 9, a roller 402 can have a circumferential surface 404 formed from a pattern of solid lattice portions 406 and apertures 408 between the solid lattice portions. The roller can also include a flame 410 or a source of infrared heat that melts and liquefies regions on the face of the textile precursor that are exposed to the flame through the apertures in the roller. After the molten polymer congeals and solidifies (i.e., fuses), the resulting floor covering 412 has fused wear layer regions 414 unfused (i.e., unheated or unmelted) fiber regions 416.

In yet another related process 500 shown in FIG. 10A, an insulated sheet 502 with patterns 504 cut into its surface may be used to create patterns or textures in the face 506 of the floor covering 508. A heat source may be directed at the fibrous precursor material through roller 510. The insulating sheet (that may be revolving or linear) may be used to at least partially block heat, while the open spaces in the sheet allow the heat to impart the desired texture, pattern, and/or design at the desired height. The areas of the fibers that contact the thinner, uninsulated, or perforated areas would receive more heat to melt and fuse fibers, while the areas of the fibers that contact the thicker and/or insulated areas would receive the least heat.

The insulating sheet may have a wide range of insulating properties, depending on the needs of the particular application. Examples of materials that may be suitable include, but are not limited to space blanket, mylar sheet, kevlar sheet, teflon coated belt, nylon belt, polytetrafluoroethylene (PTFE) sheet, polyimide sheet, metal alloy sheet, vulcanized rubber sheet, and fiberglass scrim. However, other possible materials may be used

Furthermore, a patterned insulating sheet may be used to form a floor covering having a wide variety of patterns of fused wear layer regions and unfused (i.e., unheated or unmelted fiber) regions. For instance, FIG. 10B depicts an exemplary insulting sheet 502 a including a representative star pattern 504 a formed into the Teflon™ material of the sheet. Such an insulating sheet maybe used to create a corresponding star shaped pattern in the face 506 a of a floor covering 508 a, as shown in FIG. 10C. Similarly, the insulating sheet 502 b shown in FIG. 10D includes an artistic representation 504 b formed into the Teflon™ material of the sheet 504 b that has been used to form a corresponding pattern of fused fibers in the face 506 b of the floor covering 508 b shown in FIG. 10E.

In addition to the application of heat for melting and fusing regions of fibers, the patterned sheet could also be used to apply inks or dyes to the floor covering through either the solid portions of the insulated sheet (e.g., as with a printing press) or through the openings (e.g., as with a stencil). Other possibilities are contemplated.

In another aspect of the present disclosure, heat may be applied to the surface of a used or previously installed floor covering to melt and fuse one or more areas of fibers on the face of the floor covering. In some aspects, the face may be fused to transform the appearance of the floor covering, to improve its appearance retention over time, or to rejuvenate the floor covering. In some instances, the heat treatment may be used with a floor covering that is spent or worn, or where a change in the appearance or resilience in the floor covering is desired. The heat treatment may entail using a portable heat source to fuse the surface of the floor covering in situ.

Some benefits of the heat treatment may include improved appearance retention by melting the face yarns into a more rigid structure, a more homogeneous appearance provided by removing wear paths from a used floor covering, and the ability to provide the customer with the option for a floor covering with an updated appearance. The benefits can further include increased flame resistance by reducing air flow, as well as the ability to convert a floor covering into a hard surface having at least one resilient sub-layer (e.g., the lower portions of the fibers below the fused wear layer). In areas where a resilient floor covering is being replaced, the environment may be safer, especially in locations for aged care, child care and physical activity, since the floor covering can provide an improved balance of resilience, cushioning, and ability of the customer to clean and sanitize the surface of the floor covering.

In yet another aspect of the present disclosure, heat may be used to create a user-selected pattern or design of fused wear layer regions and non-fused fiber regions in a floor covering. For example, a handheld and/or portable melting or fusion unit could be sold or provided separately or with floor covering, thereby allowing the customer to melt patterns, information, safety directions, classic art stencils, popular culture or logos into floor covering installed on a floor, ceiling, or wall. In this manner, a user can customize the floor covering design (e.g., with logos, exit strategies or directions, management communication, or safety information melted into the floor covering face), as needed or desired.

In still another aspect of the disclosure, the portions of the fibers that engage the backing on the lower side or floor-facing side of the backing (commonly referred to as the “backstitch”) may be melted or liquefied and subsequently allowed to cool and fuse together to form a fused backstitch layer. The fused backstitch layer may concurrently or subsequently be fused to the bottom surface of the primary backing to form a fused, substantially solid base sheet. In embodiments including a fused backstitch layer and/or a fused base sheet, the fused fiber wear layer may be omitted if desired.

The fused backstitch layer and/or fused base sheet may generally be formed in the same manner as the wear layer. One exemplary process for concurrently forming a resilient wear layer and a fused backstitch layer (and/or fused base sheet) may be similar to the process shown in FIG. 6, except that an additional heated roll may be used to heat the backstitch. The properties of the fused backstitch layer and/or fused base sheet may also be similar to those of the wear surface. Thus, for simplicity, the details are not repeated here.

The fusing of the backstitch fibers and the formation of the wear layer may allow non-traditional yarns or fibers (such as PET, etc.) to be used in floor coverings. Specifically, fibers that are typically deemed unsuitable due to lack of resilience may be sufficiently resilient when at least partially fused to form a wear layer. Additionally, the reduced height of the fused floor covering may improve flammability ratings, since the wear layer may provide a barrier to air flow.

Moreover, the fused base sheet may reduce or obviate the need to use a polymer precoat, which is commonly applied to the backstitch to bind the yarn and help maintain the appearance of the floor covering (e.g., as needed to reach the industry standards of quality). In such cases, the fused base sheet may simply serve as the backing of the floor covering that can then be installed to a floor surface using a suitable installation method or adhesive.

For example, a pressure sensitive adhesive may be pre-applied directly to the bottom surface of the fused base sheet and covered with a release liner for adhering the floor covering to an installation surface. Examples of pressure sensitive adhesive that may be suitable include, but are not limited to, acrylics, styrene acrylics, vinyl acetate-ethylene, acrylonitrile, styrene butadiene rubber, and the like, or any combination thereof.

Alternatively, the floor covering may be installed using an adhesive, for example, anaerobic adhesives, cyanoacrylates, one and two part toughened acrylics, epoxies, polyurethanes, one and two part silicones, phenolics, polyimides, hot melts, plastisols, rubber adhesives, polyvinyl acetates (PVAs), hard set adhesives, using tack strips or the like, using strategically or randomly placed anchors, pinchers or attachments either on the fused base sheet and/or on the floor, or any suitable combination thereof.

Alternatively still, a secondary backing may be joined to the lower side of the fused base sheet (or fused backstitch) using an adhesive or otherwise. In some embodiments, the secondary backing may be water resistant, which may be particularly suitable for use in a medical environment or in any environment where there is a need to repel liquids and/or allow cleaning and maintenance personnel to clean, sanitize, and disinfect the location without allowing fluids to the substrate and then, subsequently, facilitate the installation of the floor covering using an adhesive (e.g., a pressure sensitive adhesive). Suitable secondary backings may include, but are not limited to, a mechanically or chemically frothed or un-frothed polyurethane, styrene, styrene acrylic, acrylic, rubber, styrene butadiene rubber, PVC, olefin, polyester, or any other suitable material.

It will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. It will also be recognized by those skilled in the art that various elements discussed with reference to the various embodiments may be interchanged to create entirely new embodiments coming within the scope of the present invention. While the present invention is described herein in detail in relation to specific aspects and embodiments, it is to be understood that this detailed description is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the present invention and to set forth the best mode of practicing the invention known to the inventors at the time the invention was made. The detailed description set forth herein is illustrative only and is not intended, nor is to be construed, to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications, and equivalent arrangements of the present invention. All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are used only for identification purposes to aid the reader's understanding of the various embodiments of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention unless specifically set forth in the claims. Joinder references (e.g., joined, attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily imply that two elements are connected directly and in fixed relation to each other. Further, various elements discussed with reference to the various embodiments may be interchanged to create entirely new embodiments coming within the scope of the present invention. Many adaptations of the present invention other than those herein described, as well as many variations, modifications, and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the above detailed description without departing from the substance or scope of the present invention. Accordingly, the detailed description set forth herein is not intended nor is to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications, and equivalent arrangements of the present invention.

For example, it is to be appreciated that any suitable floor covering may be used in accordance with the present disclosure. For instance, the initial carpet or floor covering may be tufted, woven, matted, pressed, needle-punched, laminated, or may be formed in any other suitable manner. Tufted fibers may include, but are not limited to, bulk continuous filaments that have been extruded, staple fibers, air entangled fibers, twisted fibers, ribbon fibers cut into strands from large sheets or extruded from flat spinnerettes. In addition, while “floor coverings” are generally described herein, the various floor coverings may also find use as a covering for a wall or ceiling for a variety of applications. These and other revisions might be made by those of skill in the art without departing from the spirit and scope of the invention, with is constrained only by the following claims. 

What is claimed is:
 1. A floor covering comprising: a wear layer having an uppermost surface and a lowermost surface; a fiber layer comprising a plurality of fibers; and a backing, wherein the plurality of fibers have a first portion integrally joined to the lowermost surface of the wear layer, and a second portion projecting upwardly from the backing, such that the fiber layer extends between the wear layer and the backing.
 2. The floor covering of claim 1, wherein the wear layer comprises a substantially homogenous polymer layer.
 3. The floor covering of claim 1, wherein the fibers of the fiber layer are contiguous with the wear layer.
 4. The floor covering of claim 1, wherein the fibers of the fiber layer terminate at an interface between the fibers and the wear layer, such that the fibers do not extend into the wear layer.
 5. The floor covering of claim 1, wherein the wear layer and the fiber layer each have the same chemical composition.
 6. The floor covering of claim 1, wherein the fibers are formed from a polymer and the wear layer comprises the polymer of the fibers.
 7. The floor covering of claim 1, wherein the wear layer and the fiber layer define a wear side of the floor covering, wherein the wear side of the floor covering has a thickness, and the wear layer comprises at least about 10% of the thickness of the wear side of the floor covering.
 8. The floor covering of claim 1, wherein the uppermost surface of the wear layer is substantially smooth.
 9. The floor covering of claim 1, further comprising a plurality of pores extending through the wear layer so that the uppermost surface of the wear layer is in communication with the lowermost surface of the wear layer.
 10. The floor covering of claim 1, wherein the wear layer extends across the entire floor covering.
 11. The floor covering of claim 1, wherein the wear layer extends across only a portion of the floor covering.
 12. The floor covering of claim 11, wherein the wear layer is configured to define a plurality of resilient areas of the floor covering.
 13. The floor covering of claim 1, wherein the backing includes an upper side facing the wear layer and a lower side opposite the first side, and the floor covering further comprises fused backstitch layer integrally joined to the lower side of the backing sheet and to the second portion of the fibers.
 14. The floor covering of claim 13, wherein the wear layer, fiber layer, and fused backstitch layer each have the same chemical composition.
 15. The floor covering of claim 13, wherein the fused backstitch layer integrally joined to the lower side of the backing sheet defines a fused base sheet, and the floor covering further comprises an adhesive layer applied to a lower side of the fused base sheet, wherein the adhesive is for adhering the fused base sheet to an installation surface.
 16. The floor covering of claim 13, further comprising a removable release layer in a facing, contacting relationship with the adhesive layer.
 17. The floor covering of claim 13, wherein the backing is a primary backing, the fused backstitch layer integrally joined to the lower side of the backing sheet defines a fused base sheet, and the floor covering further comprises a secondary backing joined to a lower side of the fused base sheet.
 18. A method of making a floor covering, the method comprising: applying heat to a textile, the textile including a plurality of fibers extending through a backing, so that the plurality of fibers have a first portion on a first side of the backing and a second portion on a second side of the backing, wherein the first portion of the fibers includes a free end of the plurality of fibers, wherein applying heat to the textile comprises applying heat to the free end of the plurality of fibers so that the free ends of the plurality of fibers melt into a molten polymer, wherein the molten polymer solidifies and forms a wear layer integrally connected to the plurality of fibers.
 19. The method of claim 18, wherein applying heat to the free end of the plurality of fibers comprises applying heat at a temperature greater than a melting point of the fibers.
 20. The method of claim 19, wherein applying heat at temperature greater than a melting point of the fibers comprises applying heat at a temperature at least about 20° C. greater than a melting point of the fibers.
 21. The method of claim 18, wherein applying heat to the free end of the plurality of fibers comprises applying heat for from about 2 to about 10 seconds.
 22. The method of claim 18, wherein applying heat to the textile comprises applying heat to the entire surface of the textile, so that the wear layer extends across the entire floor covering.
 22. The method of claim 18, wherein applying heat to the textile comprises applying heat to less than the entire surface of the textile, so that the wear layer extends across only a portion of the floor covering.
 23. The method of claim 22, wherein applying heat to less than the entire surface of the textile defines portions of the floor covering comprising the wear layer, wherein the portions of floor covering comprising the wear layer are spaced apart by unheated portions of the plurality of fibers.
 24. The method of claim 22, wherein applying heat to less than the entire surface of the textile comprises positioning a template between the heat and the textile, wherein the template includes at least one aperture through which a portion of the plurality of fibers is exposed, so that the free ends of the portion of plurality of fibers melt into the molten polymer.
 25. The method of claim 18, further comprising applying heat to the second portion of the plurality of fibers on the second side of the backing, so that the second portion of the plurality of fibers melt into a molten polymer, wherein the molten polymer solidifies and forms a fused backstitch layer integrally connected to the second side of the backing.
 26. The method of claim 25, wherein the fused backstitch layer integrally connected to the second side of the backing defines a fused base sheet, and the method further comprises applying an adhesive a side of the fused base sheet opposite the wear layer, wherein the adhesive is for adhering the fused base sheet to a floor surface.
 27. The method of claim 26, further comprising positioning a removable release layer in a facing, contacting relationship with the adhesive layer.
 28. The method of claim 27, wherein the backing is a primary backing, and the method further comprises joining a secondary backing to a side of the fused base sheet opposite the wear layer. 